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V2.0
SINAMICS G120
Answers for industry.
SINAMICS G120
Training Booklet, V2.0
Order-no.
6SL3200-0AE20-0AA0
1LA7096-4AA10
Training case
Product
Order-no.
6ZB2480-0CJ00
6SL3244-0BB12-1BA0
Single components
Product
Order-no.
6SL3210-1PE12-3AL0
6SL3244-0BB12-1BA0
1LA7096-4AA10
SINAMICS BOP-2
Screening kit 2
6SL3264-1EA00-0HA0
Optional components
Product
Order-no.
6SL3256-0AP00-0JA0
Safety instructions
Validity
These instructions apply to the following inverter:
Product
Order-no.
6SL3200-0AE20-0AA0
Prerequisites
You are proficient in working with the Microsoft Windows operating system.
You are conversant with the principles of electronics and electrical engineering.
Warning
Dangerous currents and voltages!
The equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the warnings or failure to follow the instructions
contained in the documentation can result in loss of life, severe personal injury, or serious
damage to property.
Take particular notice of the general and regional installation and safety regulations regarding work on dangerous voltage installations (for example, EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation.
Commissioning and operation of a device/system may only be performed by qualified personnel . Within the context of the safety notes in this documentation, qualified persons are
defined as persons who are authorized to commission, ground, and label devices, systems,
and circuits in accordance with established safety practices and standards.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware
and software described. Since variance cannot be precluded entirely, we cannot guarantee
full consistency. However, the information in this publication is reviewed regularly and any
necessary corrections are included in subsequent editions.
Welcome to the SINAMIC G120 Training Booklet. This booklet will help acquaint you simply, quickly, and comfortably with the frequency inverter. Well take you step by step through
installation, setting parameters, and initial startup. The tutorial is structured so that each section
builds on the one before it. As a result, we recommend that you dont skip any chapters.
1.1 Components
Power Module.................................................................. 06
0215
Control Unit..................................................................... 07
Operator Panels (BOP-2 and IOP)..................................... 08
1.2 Mounting and wiring
Power Module.................................................................. 09
Control Unit..................................................................... 12
Operator Panels (BOP-2 and IOP)..................................... 14
1637
The device........................................................................ 33
Working with IOP............................................................. 34
The wizards..................................................................... 35
Accessing diagnostics ..................................................... 36
PC preparation................................................................. 42
3863
Configuration wizard....................................................... 52
Motor data identification................................................. 56
Appendix
Download overview.......................................................... 65
1.1
Components
The SINAMICS G120 frequency inverter is modular. It consists of three basic components:
Note
Power Module
The device is available in several sizes. Its power range is between 0.37 kW and 250 kW.
The picture shows the PM240-2.
Rating plate
Power connectors
DC link connectors
Motor connectors
PE terminals
2
3
4
3
Note
Control Unit
There are various designs for the Control Unit. They differ primarily in terms of the control
terminal assignments as well as in terms of different field bus interfaces. This tutorial will
use the example of the CU240E-2 Control Unit. It was developed for stand-alone operation.
7
3
6
4
Rating plate
USB interface
Fastening clips
2
8
8
5
Note
3
4
5
2
4
1
IOP
BOP-2
Graphical display
Display
Navigation wheel
Release catch
USB connection
RS232 connector
1.2
36,5 mm (1.44")
Example of
drilling pattern
62,3mm (2.45")
186 mm (7.32")
Note
Connect the phases and the earth conductor to the pluggable terminal clamps U2, V2, W2, and PE.
Wiring the motor
Unscrew the cover to the terminal box on the motor (the inside cover of Siemens motors
illustrates the possible wiring for the Star connection and the Delta connection).
Remove the bridge rails from the connecting block and loosen the screws.
Place the bridge rails on the terminal block and screw them into place (depending on the
type of connections required Star or Delta: in this example, a Star connection is shown).
Connect the PE connection.
Insert the cables from the power module through the opening of the terminal box
to the motor.
Slide the phases in accordance with the phase assignment in the connections.
Screw the cover back onto the motor.
The motor and Power Module are now connected together. Before continuing the commissioning of the motor and inverter, ensure that the motor and the inverter are isolated from the
line supply.
Wiring the power supply
Connect the phases and the earth conductor to the pluggable terminal clamps L1, L2, L3, and PE.
The electrical wiring is now complete.
10
3
1
Operating environment
Inverter being used
Reactors and filters used
Shielded or unshielded cable
In order to meet Class A electromagnetic compatibility requirements, you need a filter and
a shielded cable (max. length:
25 meters).
Note
The potentiometer:
Attach the positive pole of the potentiometer to terminal 1.
Attach the negative pole to 2.
Wire the output of the potentiometer arm to 3.
Close the circuit by connecting 4 to terminal 2.
Indicator lights:
Attach the power supply for the LEDs to 9.
To close the circuit, connect 9 with 20 and 22.
Wire the Faults and Warning LEDs to digital outputs 19 and 21.
Connect the negative pole to terminal 28.
12
13
14
1
3
4
Door panel
Seal
Screws
15
2.1
Basic functions
The Operator Panel is the input and display instrument for controlling the inverter. It is used in
stand-alone operation, in other words, locally, on the device, integrated in the cabinet door, or
as handheld version for series setup (IOP).
2
3
Note
2.2
ESC key
Up key
Down key
OK key
OFF key
HAND/AUTO key
ON/Run key
1
3
19
Operating pattern
To better understand the functionality of the buttons, you should be acquainted with the operating pattern: the Basic Operator Panel gives you access to a parameter list, which ranges from
0 to 9,899. Stored behind the parameters are parameter values that control the operation of the
motor. However, not all the parameters are assigned.
Parameter
Value / Index
0
0
1
0
in000
21
in001
0
in002
0
Example
r0000
r0002
P0003
P0004
P0005
P9899
Index value
Example
20
OK
OK
ESC
OK
OK
Note
Some parameters store more than one value.In this case, pressing P does not take you directly
to the value, but to an index that is displayed in brackets [00] above the actual value.
Example for index parameter
Example
OK
OK
If you want to adjust any blinking/active value digit by digit (using the UP and DOWN button
might just take too long), you can always press the OK button longer than two seconds. After
releasing the button, you can change any single digit by using the buttons OK (move to next
digit), ESC (move to previous digit), UP (increase value), and DOWN (decrease value).
Note
Screen Icons
The BOP-2 displays a number of icons on the left-hand side of the display to indicate the actual
state of the inverter.
Command source
Inverter status
Jog
JOG
Fault/alarm
Note
Menu structure
Monitor
The Monitor menu allows the user to easily access a variety of screens that display the actual
status of the inverter/motor system.
Control
The Control menu allows the user to access the following functions of the inverter:
Setpoint
Jog
Reverse
Diagnostics
The Diagnostics menu allows the user to access the following function:
Acknowledge all faults
Faults
History
Status
Parameters
The Parameter menu allows access to view and change the parameters of the inverter.
Setup
The Setup menu is a fixed sequence of screens that allow the user to perform the basic
commissioning of the inverter.
Extras
The Extras menu allows the user to perform additional functions such as saving and copying
data sets into and from the BOP-2.
23
2.3
Quick commissioning
The following descriptions show how to set up the drive using the quick commissioning wizard
integrated in the BOP-2.
Starting quick commissioning
Press ESC to enter the menu selection.
Use the UP and DOWN buttons to move the menu cursor to the word Setup and press OK.
The screen will automatically display the next parameter in the commissioning sequence.
ESC
OK
Quick commissioning begins now. It leads you step by step from parameter to parameter.
Parameters that are not relevant will be skipped automatically. Essentially, you are adjusting
the factory settings of your inverter to the requirements of your motor.
Reset inverter
Reset the inverter to factory state by first pressing OK while the BOP-2 shows RESET.
Press UP or DOWN to change the value to YES.
Press OK and wait until BUSY sign disappears (approx. five seconds).
OK
OK
OK
Note
OK
OK
Note
Once the motor rated speed has been adjusted, you have completed
adjusting your inverter to your motor.
Note
OK
Motor identification will not start until the basic commissioning sequence has been
completed.
Start the motor manually (by using digital input DI 0 or by activating the HAND mode
and starting the drive using the ON button).
The measuring process is set in motion.
When finished, the motor switches off.
BOP-2 indicates that the measured values are now being converted into data.
HAND
AUTO
The inverter can now be turned on using digital input DI 0. The setpoint
source is specified as the potentiometer.
Note
OK
The next step is checking the setpoint source. This is stored with P1000.
Checking the setpoint source (P1000)
Press OK to modify the parameter value MAIN SP.
Check if it shows ANALOG and the value 2.
The 2 indicates that the potentiometer on the terminal is currently set as the
setpoint source.
Confirm by pressing OK.
OK
OK
Now you should adjust the operating behavior of the motor to your application.
Additional setpoint source (P1000)
Press OK to modify the parameter value ADD SP.
This parameter gives you the possibility to add a second setpoint source by pressing
UP or DOWN.
Leave the value at NONE (0) and confirm by pressing OK.
OK
28
OK
OK
Set the ramping-up time under parameter RAMP UP for acceleration time to maximum
frequency (P1120).
Set the ramping-down time under parameter RAMP DWN for time until standstill (P1121).
OK
OK
OK
OK
The values are displayed in seconds. In both cases, the times indicated
should not be too short, because this might result in an alarm.
Finishing
Press OK when the BOP-2 shows FINISH.
Confirm by using the UP or DOWN button to select YES and press
OK again.
OK
OK
Note
2.4
Application case
Youll now see how you can use the Basic Operator Panel 2 to make additional adjustments. In
specific applications, it is meaningful, for example, to control the motor using fixed frequencies.
Fixed frequencies are preset at digital inputs DI 3, DI 4, and DI 5. Therefore, the setpoint source
must be switched from the potentiometer to the digital inputs on the terminals. This can be accomplished quickly and simply using the Basic Operator Panel 2. As previously mentioned, you
define the setpoint source using parameter P1000.
OK
OK
OK
OK
OK
OK
OK
The setpoint source has been transferred from the potentiometer to fixed frequencies at digital
inputs DI 3, DI 4 and DI 5. If you now attempt to control the motor using the potentiometer, you will
see that the motor does not react. The next step is to determine the revolution speed associated
with the digital inputs: 300, 600, 900 1/min.
Setting fixed numbers of revolutions
The digital inputs of switches DI 3, DI 4, and DI 5 are assigned the revolution speed of
0 1/min by default.
You can see this by consulting P1001, P1002, and P1003.
Change these values by pressing OK, UP, and DOWN to P1001=300, P1002=600, P1003=900.
OK
30
OK
OK
The Basic Operator Panel 2 can also be used to make a variety of other adjustments to your application. An overview of the parameters can be found in the Operating Instructions: Control
Units CU240E.
OK
OK
OK
The BOP-2 can be mounted or removed at any time. The device is not
necessary for ongoing operation.
Note
2.5
32
The device
The IOP is a menu-driven device. Its functionality is structured by three o
ptions:
The display
All necessary information is displayed in user-friendly plain text or icons. The displayed icons
are shown at the top right-hand edge of the display. They indicate various states of the inverter.
Command source auto/hand
Inverter status ready/running
Fault
Alarm pending
Battery condition Fully Charged/Discharged
33
2
The HAND/AUTO function
works the same as the one
implemented in the BOP-2.
After starting the motor
with the ON button, you
can change the setpoint
speed by navigating to
CONTROL/SETPOINT and
turning the wheel (right
to increase speed, left to
decrease speed).
34
Note
The wizards
There are several wizards that allow you to set up various functions and commission the inverter. They navigate you interactively through the parameterization of standard applications. The
wizards are accessed from the wizards menu, at the bottom-left of the status screen.
Example: Basic commissioning
Use the wheel to highlight the word WIZARDS.
Confirm by pressing OK.
Navigate to BASIC COMMISSIONING by turning the wheel.
Confirm by pressing OK.
OK
Wizards
OK
OK
Basic Commisioning
OK
Now the wizards will guide you step by step through the basic commissioning process by presenting a number of screens where you can choose the necessary options and values. At the
conclusion of the basic commissioning process, the data can be saved to the inverter's memory,
and calculation of motor and control data is started.
Always use the wheel to select an option and press OK to confirm.
Press ESC to move back one step.
Press INFO to read context-sensitive help information.
Note
Accessing diagnostics
If you want to find out which input and output devices are connected to the inverter, simply navigate to the diagnostics menu and select the I/O STATUS. This option displays a list of the digital
and analog inputs and outputs of the inverter. In addition, you can monitor their current status.
This is an information screen and cannot be changed.
Reading the I/O status
Use the wheel to highlight the word MENU.
Confirm by pressing OK.
Select DIAGNOSTICS.
Confirm by pressing OK.
Choose I/O STATUS.
Confirm by pressing OK.
Choose STATUS DIGITAL INPUTS.
Confirm by pressing OK.
OK
Menu
OK
OK
Diagnostics
OK
I/O Status
OK
OK
OK
OK
You can now see a clearly arranged overview of all connected I/O
including their status.
Note
OK
Menu
OK
OK
Active Faults/Alarms
Diagnostics
OK
OK
Now all active fault messages that have not yet been acknowledged are displayed.
To get further information you can highlight each one and press INFO.
You now know how to use the Operator Panels to set the parameters on your inverter and start it
up. A further possibility is setting up the parameters using your PC or a SIMATIC programming
device. This method is clearer and more convenient, but requires somewhat more preparation
time.
Note
3.1
40
A connecting cable
Hardware preparation
Connect the USB cable to the USB connection at the Control Unit.
Connect the other end to the USB interface of your PC.
In addition to the hardware, youll also need the STARTER software, which is included on a DVD
in the PC Connection Kit 2. Install the STARTER software on your PC following the explanations of
the setup wizard.
Note
PC preparation
To connect the STARTER tool to the inverter you need to make sure that the USB-COM emulation
connects to a COM port smaller than eight (COM1 COM7). You need to remember that number
for later use with the STARTER.
1
Select "Hardware."
Check if Sinamics G120 USB COM Emulation has an address higher than COM7.
42
Change the COM address by choosing any free small COM address.
43
44
45
46
47
Click Continue to start the search for online units: a preview of the project tree will appear in the summary.
48
Project tree
Program menu
Connection mode
Work area
2
3
49
Click icon Connect to target system. A dialog window opens and the current inverter data is displayed.
In addition, the blue highlighted Offline mode changes to the yellow highlighted Online mode; the workbench area
opens.
Workbench area
This area provides additional information like alarms, the target system output, and the diagnostics overview. It also stores additional operating features.
2
3
3
50
We recommend setting up
parameters using the online
mode.
Note
Note
3.2
Parameterization
The STARTER software and the inverter are now connected to each other. You can now begin
to parameterize your inverter.
1
Double-click on the inverter icon in the project tree: a directory folder opens.
Double-click on the first icon: the configuration window in the work area opens.
51
Configuration Wizard
The Configuration Wizard guides you step by step through the following parameters:
Control structure
Defaults of the setpoint source and the command source
Motor
Motor data
Drive functions
Important parameters
Calculation of the motor data
Summary
52
53
Alarm message
The warning message warning 541 appears. The message indicates that the motor might
turn when motor data identification is performed.
54
Enter maximum current normally 200%, minimum and maximum frequency, ramp-up and ramp-down time, and OFF
ramp-down time (the time the motor needs to stop in the case of an emergency shut-off).
After clicking Next, the calculating of the motor data starts. This concludes the parameterization with the Configuration Wizard. You will now receive a summary of all parameter values input. The summary can be inserted into a text file
by pressing the Copy text to clipboard button. Finally, close the window by clicking Finish.
55
Double-click Control panel to open the control panel in the workbench area.
1
2
Note
A setup window for command transfer opens: accept the displayed values and safety instructions.
Now the STARTER software has control authority for the attached motor.
6
Motor data identification is processed. The motor will stop running automatically
after the process has been completed. Your inverter is now ready for operation.
5
6
57
3.3
Safety Integrated
All control units CU240E-2 come with the Safety Integrated function STO (Safe Torque Off).
Activating the STO function immediately ensures that the motor cannot supply any further
torque-generating energy.
Advantages for the user:
No wearing parts, thanks to electronic shutdown
Inverter remains connected to the supply, and always supports full diagnostics capability
Password protected, no manipulation of the function possible
We strongly recommend that Safety Integrated engineering only be performed using the
STARTER tool. In so doing, you are guided by graphical explanations and the risk of wrong
inputs is reduced to a minimum.
STO can be used in cases where motor can decelerate to a standstill by itself within a sufficiently short period of time on account of the load torque or friction, or in situations where
safety issues do not arise as a result of the motor coasting down.
STO
58
Note
If you require the status signal STO active in your higher-level controller, link it up accordingly.
2
1
3
4
Did you know that the extended SINAMICS Safety Integrated functions
can be used without the need of an
encoder at the motor? This worldwide unique feature saves installation and engineering time, reduces
system costs and saves space.
For further instructions consult the
Safety functions manual SINAMICS
G120 using the Siemens Product Information System (Prodis) at http://
support.automation.siemens.com/
WW/view/en/22339653/130000
Note
Note
3.4
Application cases
Before returning control authority from the STARTER software to the terminal, you should try
controlling the motor from the PC.
All functions from the displayed control area in the STARTER will be deactivated.
The control authority has been returned to the terminal.
3
4
60
Save the parameter settings in the inverters EEPROM memory by selecting Save data in drive (RAM to ROM).
AND save the parameter setting in your project by clicking Save data to project.
2
Now you can disconnect the
online connection to the
inverter by clicking the Disconnect from target system icon.
In our example, please continue
to remain online to restore the
inverter to its factory settings.
Note
3
1
62
The security query that is now displayed lets you know that all settings you have made will
be reset. Using the checkbox query, you will have the opportunity beforehand to save your
settings to the inverters ROM memory.
4
You now know how to use STARTER to quickly and clearly insert your inverter into a project,
set up its parameters, and put it into operation. Please make sure that you always remember
to save the parameter data to the inverter and in the software before exiting a project.
63
Congratulations!
You have mastered the SINAMICS G120 Training
Booklet V2.0. Thank you for your time and
efforts. We hope that this tutorial has addressed
all the questions you had and was useful to you.
More detailed information can be found online.
Download overview
Additional information on parameters
Parameter Manual: Control Units CU240B/E-2
available on the Internet as a download at
http://support.automation.siemens.com/WW/view/en/30563628/133300
Detailed information about SINAMICS G120
Operating Instructions: Control Unit CU240E
available on the Internet as a download at
http://support.automation.siemens.com/WW/view/en/30563628/133300
STARTER Software
STARTER is available as a download at
http://support.automation.siemens.com/WW/view/en/10804985/133100
www.hl-studios.de
Siemens AG
Industry Sector
Drive Technologies
Motion Control
www.siemens.com/sinamics-g120